One-Piece Connecting Element With Tolerance Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fluid assemblies in systems like anti-lock brake systems face challenges with inflexible and complex electrical connections between magnet coils and printed circuit boards, requiring stamped grids that are difficult to vary and prone to mechanical stresses, and often necessitate additional connection pieces.
Innovation Solution
A one-piece connecting element with three-dimensionally shaped tolerance compensation elements that allow for length and positional compensation, enabling mechanical decoupling and reduced forces, and utilizing cold contact-making connections like insulation displacement or plug connections without the need for welding or soldering, with the bent portion of the meander shaped to form an omega for optimal flexibility and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stamped-grid strips are used for electrical connection, then electrical connection is achieved, but mechanical stresses and forces increase in the contact region
Solution Approach 1:
A flexible printed circuit board (FPC) is introduced as an intermediary element between the magnet coil and the printed circuit board. The FPC serves as a mediator that transmits electrical signals while absorbing mechanical stresses through its flexibility, preventing force transmission to the contact region. This resolves the contradiction by decoupling the electrical connection function from the mechanical stress path.
Solution Approach 2:
The patent changes the physical parameters of the connection system by using a flexible printed circuit board with specific mechanical properties (flexibility, elasticity) rather than rigid stamped-grid strips. This parameter change allows the connection to accommodate mechanical stresses without transmitting them to the contact region, maintaining electrical reliability while reducing mechanical forces.
2Reliability
If stamped grids are used for electrical connection, then electrical connection is established, but device complexity increases due to additional connection pieces
Solution Approach 1:
The patent merges multiple functions into a single flexible printed circuit board component. The FPC integrates the electrical connection function, mechanical coupling function, and signal transmission function that were previously distributed across multiple separate components (stamped grids, connection pieces, wiring). This consolidation reduces device complexity while maintaining reliable electrical connection.
Solution Approach 2:
The flexible printed circuit board serves multiple functions simultaneously: it provides electrical connection, acts as a mechanical coupling element, absorbs thermal expansion, and transmits signals. This multi-functionality eliminates the need for separate specialized components, reducing overall device complexity while ensuring reliable electrical connection.
3Stability of the object's composition
If rigid connection structures are used, then structural stability is maintained, but adaptability to positional tolerances decreases
Solution Approach 1:
The patent employs a flexible printed circuit board that functions as a flexible thin film structure. This flexible film can bend and deform to accommodate positional tolerances between components while maintaining structural integrity and electrical connection. The flexibility allows adaptation to manufacturing variations without compromising structural stability.
4Reliability
If welding or soldering processes are used for connection, then strong electrical connection is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces thermal joining processes (welding, soldering) with a mechanical insertion system. The flexible printed circuit board is inserted into a receptacle and retained by elastic retention elements, eliminating the need for thermal processes. This substitution simplifies manufacturing while maintaining strong electrical connection through the mechanical and elastic retention system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides improved mechanical decoupling, reduced mechanical stresses, and cost-effective assembly by eliminating the need for stamped grids and additional connection pieces, while allowing for tolerance compensation and reduced force transmission, enhancing the flexibility and modularity of the assembly.
Implementation Method 1
a first variable tolerance compensation element permitting length compensation in at least one direction in space in order to prespecify a desired spatial positioning of the first contact element and of the second contact element in relation to one another, and with the first variable tolerance compensation element being three-dimensionally shaped by bending
Implementation Method 2
The three-dimensional design of the first variable tolerance compensation element results in operation in the manner of a torsion spring and therefore considerably improved mechanical decoupling and a reduction in forces in the contact region of the first contact element
Data Source
AI summary
A connecting element for electrically connecting two components to a first electric contact element for electrically contacting a first component, to a second electric contact element for electrically contacting a second component, and to at least one tolerance compensating element is disclosed. The fluid assembly includes at least one such connecting element. The connecting element is configured as one piece and the first electric contact element and the second electric contact element are connected to each other by way of the at least one tolerance compensating element. The first variable tolerance compensating element enables a compensation in length in at least one spatial direction in order to predetermine a desired spatial position of the first contact element and the second contact element in relation to each other. The first variable tolerance compensating element may be three-dimensionally shaped by bending.